Removable composite insulated concrete form, insulated precast concrete table and method of accelerating concrete curing using same

ABSTRACT

The invention comprises a concrete form. The concrete form comprises a first panel having a first primary surface for contacting plastic concrete and a second primary surface opposite the first surface, wherein the first panel is made from a rigid plastic sheet or a metal sheet; and a second panel spaced from the second primary surface of the first panel, wherein the second panel is made from a rigid plastic sheet or a metal sheet. The concrete form also comprises a layer of insulating material disposed between the first panel and the second panel. A method of using the concrete form is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of the filing date of U.S.provisional patent application Ser. No. 61/822,858 filed May 13, 2013.

FIELD OF THE INVENTION

The present invention generally relates to a form for cement-basedmaterials. More particularly, this invention relates to a concrete form,particularly an insulated concrete form. The present invention alsorelates to a method of curing concrete. The present invention alsorelates to a method for accelerating concrete curing using a removableinsulated concrete form. The present invention also related to a methodof curing concrete with reduced amounts of portland cement, whichproduces a concrete that cures faster and is stronger and more durable.

BACKGROUND OF THE INVENTION

Concrete is a composite material consisting of a mineral-based hydraulicbinder which acts to adhere mineral particulates together in a solidmass; those particulates may consist of coarse aggregate (rock orgravel), fine aggregate (natural sand or crushed fines), and/orunhydrated or unreacted cement. Concrete typically is made from portlandcement (“PC”), water and aggregate. Curing concrete requires twoelements: suitable temperature and water. To achieve maximum strength,all cement particles must be hydrated. The initial process of hydrationis exothermic; it generates a considerable amount of energy called “heatof hydration.” Fluid (plastic) concrete is poured in various forms ormolds and left to set until it has hardened sufficiently to remove theconcrete forms. These prior art forms are not insulated and thereforeconcrete is exposed to the environment. Consequently, the energygenerated from the heat of hydration is generally lost to theenvironment in the first 12-20 hrs. Generally, the concrete forms areremoved exposing the concrete to the environment. In the next few days,most of the initial concrete moisture is also lost from the concrete.Therefore, the two elements required to fully hydrate the cement arelost during the initial stage of concrete curing. Thus, the cement maynever fully hydrate, and, therefore, may never achieve maximum strength.Portland cement concrete achieves 90% of maximum strength under idealcuring conditions in about 28 days.

Portland cement manufacture causes environmental impacts at all stagesof the process. During manufacture, a metric ton of CO₂ is released forevery metric ton of portland cement made. Worldwide CO₂ emissions fromportland cement manufacture amount to about 5-7% of total CO₂ emissions.The average energy input required to make one ton of portland cement isabout 4.7 million Btu—the equivalent of about 418 pounds of coal. Theproduction of portland cement is energy intensive, accounting for 2% ofprimary energy consumption globally. In 2010 the world production ofhydraulic cement was 3,300 million tons.

Concrete can also be made with slag cement (“SC”) and fly ash (“FA”) butare not frequently used. Slag cement and fly ash generate relatively lowamounts of heat of hydration, which result in extremely slow settingtime and strength gain. Slag cement and fly ash can be mixed withportland cement but industry practice in building construction limitsuse of slag cement and fly ash to no more than 30% replacement ofportland cement and only during warm weather conditions. Concrete madewith slag cement and fly ash may take up to 90 days to achieve 80-90% ofmaximum strength. Mass concrete structures use more slag cement and flyash, replacing up to 80% of portland cement, as a means to reduce theheat of hydration to reduce cracking. Slag cement and fly ash use lesswater to hydrate, may have finer particles than portland cement andproduce concretes that achieve higher compressive and flexural strength.Such concrete is also less permeable, and, therefore, structures builtwith slag cement and fly ash have far longer service lives.

Slag cement is obtained by quenching molten iron slag (a by-product ofiron and steel-making) from a blast furnace in water or steam, toproduce a glassy, granular product that is then dried and ground into afine powder. Slag cement manufacture uses only 15% of the energy neededto make portland cement. Since slag cement is made from a wastematerials; no virgin materials are required and the amount of landfillspace otherwise used for disposal is reduced. For each metric ton of pigiron produced, approximately ⅓ metric ton of slag is produced. In 2009,worldwide pig iron production was 1.211 billion tons. There was anestimated 400 million tons of slag produced that could potentially bemade into slag cement. However, only a relatively small percentage ofslag is used to make slag cement in the USA.

Fly ash is a by-product of the combustion of pulverized coal in electricpower generation plants. When pulverized coal is ignited in a combustionchamber, the carbon and volatile materials are burned off. However, someof the mineral impurities of clay, shale, feldspars, etc. are fused insuspension and carried out of the combustion chamber in the exhaustgases. As the exhaust gases cool, the fused materials solidify intospherical glassy particles called fly ash. The quantity of fly ashproduced is growing along with the steady global increase in coal use.According to Obada Kayali, a civil engineer at the University of NewSouth Wales Australian Defense Force Academy, only 9% of the 600 milliontons of fly ash produced worldwide in 2000 was recycled and even smalleramount used in concrete; most of the rest is disposed of in landfills.Since fly ash is a waste product, no additional energy is required tomake it.

Historically, concrete has been made using natural cements and otherpozzolanic materials, such as volcanic ash, certain type of reactiveclays, rice husk ash, metakolin, silica fume and others. Pozzolanicmaterials have a very low rate of hydration and generate less heat ofhydration. Therefore concrete made with pozzolanic materials are seldomused due to their slower curing process.

More recently pozzolanic materials, such a fly ash and volcanic ash havebeen modified through a process of fracturing which produces what iscalled “energetically modified cement.” Such pozzolanic materials aretypically of a generally spherical shape but can be fractured so thatthe round sphere particle is broken up into multiple particles with moresurface area. The greater surface area creates a higher reactiveparticle, therefore increasing the hydration properties of thepozzolanic material.

Concrete walls, and other concrete structures and objects, traditionallyare made by building a form or a mold. The forms and molds are usuallymade from wood, plywood, metal and other structural members. Unhardened(plastic) concrete is poured into the space defined by opposed spacedform members. Once the concrete hardens sufficiently, although notcompletely, the forms are removed leaving a concrete wall or otherconcrete structure, structural member or concrete object exposed toambient temperatures. Concrete forms are typically made of various typesof plywood or metal supported by a frame. These forms are not insulatedwhich means that concrete is exposed to the elements during the initialportion of the curing process. This often makes the curing of theconcrete a slow process and the ultimate strength difficult to controlor predict. To compensate for these losses and increase the rates ofsetting and strength development, larger amounts of portland cement areused than otherwise would be necessary.

The curing of plastic concrete requires two elements, water and heat, tofully hydrate the cementitious material. The curing of plastic concreteis an exothermic process. This heat is produced by the hydration of theportland cement, or other pozzolanic or cementitious materials, thatmake up the concrete. Initially, the hydration process produces arelatively large amount of heat. Concrete placed in conventional forms(i.e., uninsulated forms) loses this heat of hydration to theenvironment in a very short time, generally in the first 8-24 hours,depending on the ambient temperature. Also, due to the heat loss to theenvironment the concrete placed in conventional forms does not reach itsmaximum potential temperature. As the hydration process proceeds,relatively less heat of hydration is generated due to slowing reactionrates. At the same time, moisture in the concrete is lost to theenvironment. If one monitors the temperature of concrete during thecuring process, it initially produces a relatively large increase intemperature which then decreases relatively rapidly over time. Thischemical reaction is temperature dependent. That is, the hydrationprocess, and consequently the strength gain, proceeds faster at highertemperature and slower at lower temperature. In conventional forms, bothheat and moisture are lost in a relatively short time, which makes itdifficult, or impossible, for the cementitious material to fullyhydrate, and, therefore, the concrete may not achieve its maximumpotential strength.

Concrete in conventional concrete forms or molds is typically exposed tothe elements. Conventional forms or molds provide little or noinsulation to the concrete contained therein. Therefore, heat producedwithin the concrete form or mold due to the hydration process usually islost through a conventional concrete form or mold relatively quickly tothe environment. Thus, the temperature of the plastic concrete mayinitially rise 20 to 40° C., or more, above ambient temperature due tothe initial hydration process and then fall relatively quickly toambient temperature, such as within 8 to 36 hours depending on theclimate and season and size of the concrete element. This initialrelatively large temperature drop may result in significant concreteshrinkage and/or thermal effects which can lead to concrete cracking.The remainder of the curing process is then conducted at approximatelyambient temperatures, because the relatively small amount of additionalheat produced by the remaining hydration process is relatively quicklylost through the uninsulated concrete form or mold. The concrete istherefore subjected to the hourly or daily fluctuations of ambienttemperature from hour-to-hour, from day-to-night and from day-to-day.Failure to cure the concrete under ideal temperature and moistureconditions affects the ultimate strength and durability of the concrete.In addition the temperature gain and loss in the first few days ofconcrete curing creates thermal stresses within the concrete. At thetime that the concrete reaches its maximum temperature, usually 8-16hrs, the concrete is in a relatively weak state and cannot withstand thethermal stresses very well. The cooling of the concrete from the initialtemperature peak creates temperature shrinkage cracking within thecement paste. The further heat loss and gain due to the ambienttemperature fluctuations from day and night places additional thermalstresses upon the concrete and further contributes to temperatureshrinkage cracking. While initially temperature shrinkage cracking is ona nano scale, with time, the nano cracks develops into fractures thatweaken the concrete and shorten its lifespan.

In colder weather, concrete work may even come to a halt since concretewill freeze, or not gain much strength at all, at relatively lowtemperatures. By definition (ACI 306), cold weather conditions existwhen “ . . . for more than 3 consecutive days, the average dailytemperature is less than 40 degrees Fahrenheit and the air temperatureis not greater than 50 degrees Fahrenheit for more than one-half of any24 hour period.” Therefore, in order for hydration to take place, thetemperature of concrete must be above 40° F.; below 40° F., thehydration process slows and at some point may stop altogether. Underconventional forming and curing methods, the concrete takes a relativelylong time to fully hydrate the cementitious materials. Since both theinitial heat and moisture are quickly lost in conventional forms, it istypically recommended that concrete by moisture cured for 28 days tofully hydrate the concrete. However, moisture curing for 28 days isseldom possible to administer in commercial practice. Therefore,concrete poured in various applications in conventional forms seldomdevelops it maximum potential strength and durability.

Insulated concrete form systems are known in the prior art and typicallyare made from a plurality of modular form members. U.S. Pat. Nos.5,497,592; 5,809,725; 6,668,503; 6,898,912 and 7,124,547 (thedisclosures of which are all incorporated herein by reference in theirentirety) are exemplary of prior art modular insulated concrete formsystems. Full-height insulated concrete forms are also known in theprior art. U.S. Patent Application Publication No. 2013/0074432 and U.S.Pat. No. 8,555,583 (the disclosures of which are both incorporatedherein by reference in their entirety) disclose full-height insulatedconcrete forms. However, these insulated concrete forms are stay inplace concrete forms whereby the insulating panels are attached to theconcrete and are not easily removed. In addition if these insulatedpanels are removed from the concrete, they are usually damaged and notable to be reused.

Although insulated concrete forms work well and provide many benefits,concrete contractors and architects are somewhat reluctant to use themor specify them. Especially, stay in place insulated concrete formscannot be used for applications that require removal of the formwork.Under conventional forming and curing methods, the concrete takes arelatively long time to fully hydrate the cementitious materials. Sinceboth the initial heat and moisture is often relatively quickly lost, itis typically recommended that concrete be moist cured for 28 days tofully hydrate the cement. However, moisture curing for 28 days is seldompossible to achieve in commercial practice. Therefore, for concretepoured for various applications it can be very difficult, or impossible,to achieve its maximum potential strength and durability. Currentinsulated concrete forms are made of polymeric foam and remain in placeafter concrete is placed. However, there are many types of applicationsthat do not need the insulation provided by insulated concrete forms toremain in place as part of the structure.

It is believed that prior art concrete forms have not been proposed orused as a method to cure concrete or to improve the performance andproperties of concrete. The present invention has discovered that whenretaining in an insulated concrete form the initial heat generated bythe hydration of cementitious material, the concrete achieves a greaterinternal temperature and such temperature is sustained for much longerperiods of time before it is lost to the environment. During this time,there is sufficient moisture in the concrete to hydrate the cementitiousmaterial. When the insulated concrete forms are removed, usually a fewdays after the pour, the concrete and cement paste would have alreadyachieved a relatively high level a cement hydration with a relativelyhigh corresponding compressive strength. A more fully hydrated cementpaste and higher strength concrete is better able to withstand thestresses associated with temperature loss. Thus, the inevitabletemperature shrinkage cracking associated with concrete forming isgreatly reduced or eliminated.

Many concrete contractors prefer to use the prior art plywood-type formboard and frame concrete form because it is the form with which they andthe construction workforce are familiar. Therefore, it would bedesirable to produce a concrete form that combines the benefits of aninsulated concrete form with a removable conventional concrete formframe type that can retain the initial heat of hydration to acceleratethe hydration and curing process and more fully cure concreteimmediately after concrete is placed in the forms. It also would bedesirable to reduce or eliminate temperature shrinkage crackingassociated with conventional concrete forming. Any type of concreteplaced in such forms will have far greater and improved properties andbe more durable and longer lasting. It is also desirable to makeconcrete from as much post industrial waste as possible thereby reducingthe burden on landfill. It would also be desirable to reduce the amountof portland cement used in concrete as much as possible to therebyreduce the amount of CO₂ emissions associated with manufacture ofportland cement.

SUMMARY OF THE INVENTION

The present invention satisfies the foregoing needs by providing animproved concrete forming system to retain the heat of hydration ofcuring concrete.

In one disclosed embodiment, the present invention comprises a concreteform. The form comprises a first panel having a first primary surfacefor contacting plastic concrete and a second primary surface oppositethe first surface and a layer of insulating material on the secondprimary surface.

In another disclosed embodiment, the present invention comprises aconcrete form. The form comprises a first panel having a first primarysurface for contacting plastic concrete and a second primary surfaceopposite the first primary surface, wherein the first panel is made froma rigid plastic sheet or a metal sheet. The concrete form also comprisesa second panel spaced from the second primary surface of the firstpanel, wherein the second panel is made from a rigid plastic sheet or ametal sheet. The concrete form also comprises a layer of insulatingmaterial disposed between the first panel and the second panel.

In another disclosed embodiment, the present invention comprises aconcrete form. The concrete form comprises a panel for contactingplastic concrete, the panel having a primary surface, wherein the panelis made from a rigid plastic sheet or a metal sheet and a layer ofinsulating material composed of ceramic fibers suspended in a polymericfoam or in an adhesive disposed on and substantially covering theprimary surface.

In another disclosed embodiment, the present invention comprises aconcrete form. The form comprises a panel for contacting plasticconcrete, the panel having a primary surface, wherein the panel is madefrom a rigid plastic sheet or a metal sheet and a layer of refractoryinsulating material disposed on and covering the primary surface.

In another disclosed embodiment, the present invention comprises amethod of forming concrete. The method comprises placing plasticconcrete between a pair of opposed concrete forms. Each of the concreteforms comprises a first panel having a first primary surface forcontacting plastic concrete and a second primary surface opposite thefirst primary surface, wherein the first panel is made from a rigidplastic sheet or a metal sheet. The concrete form also comprises asecond panel spaced from the second primary surface of the first panel,wherein the second panel is made from a rigid plastic sheet or a metalsheet. The concrete form also comprises a layer of insulating materialdisposed between the first panel and the second panel. The methodfurther comprises leaving the concrete forms in place for a timesufficient to at least partially cure the plastic concrete.

In another disclosed embodiment, the present invention comprises amethod of forming concrete. The method comprises placing plasticconcrete between a pair of opposed concrete forms. Each of the concreteforms comprises a panel for contacting plastic concrete, the panelhaving a primary surface, wherein the panel is made from a rigid plasticsheet or a metal sheet and a layer insulating material composed ofceramic fibers suspended in a polymeric foam or in an adhesive disposedon and substantially covering the primary surface. The method furthercomprises leaving the concrete forms in place for a time sufficient toat least partially cure the plastic concrete.

In another disclosed embodiment, the present invention comprises amethod of forming concrete. The method comprises placing plasticconcrete between a pair of opposed concrete forms. Each of the concreteforms comprises a panel for contacting plastic concrete, the panelhaving a primary surface, wherein the panel is made from a rigid plasticsheet or a metal sheet and a layer of refractory insulating materialdisposed on and covering the primary surface. The method furthercomprises leaving the concrete forms in place for a time sufficient toat least partially cure the plastic concrete.

Therefore, it is an object of the present invention to provide animproved insulated concrete form.

Another object of the present invention is to provide a removableinsulated concrete form that can be used in the same manner as prior artframe plywood-type form board concrete forms.

A further object of the present invention is to provide a method ofcuring concrete by retaining the heat of hydration within the concretethereby accelerating the hydration and curing of cementitious materialsto achieve concrete with improved properties.

Another object of the present invention is to provide an improved methodfor curing concrete by more fully hydrating the cementitious materialbefore needed heat and moisture are lost to the environment.

Another object of the present invention is to provide a system forcuring concrete such that the concrete develops its maximum strength asearly as possible.

Another object of the present invention is to provide a concrete formingsystem for curing concrete that reduces or eliminates temperatureshrinkage cracking associated with conventional concrete forming.

A further object of the present invention is to provide a concretecuring system that uses reduced amounts of portland cement whileproducing concrete having an ultimate strength equivalent to concretemade with conventional amounts of portland cement.

Another object of the present invention is to provide a concrete curingsystem that substantially reduces the use of portland cement whileproducing concrete having an ultimate strength equivalent to concretemade with conventional amounts of portland cement.

A further object of the present invention is to provide a concretecuring system that uses relatively large amounts of recycled industrialwaste material, such as slag cement, fly ash, volcanic ash,energetically modified cements, silica fume, pulverized glass and/orrice husk ash, while producing concrete having an ultimate strengthequivalent to, or better than, concrete made with conventional amountsof portland cement.

A further object of the present invention is to provide a concretecuring system that uses inert or filler material, such as groundlimestone, calcium carbonate, titanium dioxide, or quartz, whileproducing concrete having an ultimate strength equivalent to, or betterthan, concrete made with conventional amounts of portland cement.

A further object of the present invention is to provide a concretecuring system that uses relatively large amounts of recycled industrialwaste material, such as slag cement, fly ash, volcanic ash,energetically modified cements, silica fume, pulverized glass and/orrice husk ash, in combination with inert or filler material, such asground limestone, calcium carbonate, titanium dioxide, or quartz, whileproducing concrete having an ultimate strength equivalent to, or betterthan, concrete made with conventional amounts of portland cement.

Another object of the present invention is to provide a system forcuring concrete such that concrete mixes containing reduced amounts ofportland cement can be cured efficiently and effectively therein whilehaving compressive strengths equivalent to, or better than, conventionalconcrete mixes.

Yet another object of the present invention is to provide a system forcuring concrete such that the concrete develops its maximum durability.

Another object of the present invention is to provide a system forcuring concrete more quickly.

Another object of the present invention is to provide an improvedconcrete form.

Another object of the present invention is to provide an insulatedconcrete form that provides insulation for both radiant heat loss andconductive heat loss.

These and other objects, features and advantages of the presentinvention will become apparent after a review of the following detaileddescription of the disclosed embodiments and the appended drawing andclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially broken away perspective view of a typical priorart concrete form having a plywood panel and steel frame construction.

FIG. 2 is a partially broken away cross-sectional view taken along theline 2-2 of the prior art concrete form shown in FIG. 1.

FIG. 3 is a cross-sectional view taken along the line 3-3 of the priorart concrete form shown in FIG. 1.

FIG. 4 is a partially broken away perspective view of a disclosedembodiment of an insulated concrete form in accordance with the presentinvention.

FIG. 5 is a partially broken away cross-sectional view taken along theline 5-5 of the insulated concrete form shown in FIG. 4.

FIG. 6 is a cross-sectional view taken along the line 6-6 of theinsulated concrete form shown in FIG. 4.

FIG. 7 is a lateral cross-sectional view of a disclosed embodiment of aninsulated precast casting table utilizing the form disclosed in FIGS. 5and 6 in a horizontal configuration.

FIG. 8 is a cross-sectional view taken along the line 8-8 of theinsulated precast casting table shown in FIG. 7.

FIG. 9 is a lateral cross-sectional view of another disclosed embodimentof an insulated precast casting table utilizing the form disclosed inFIGS. 5 and 6 in a horizontal configuration.

FIG. 10 is a cross-sectional view taken along the line 10-10 of theinsulated precast casting table shown in FIG. 9.

FIG. 11 is a graph of concrete temperature versus elapsed concretecuring time of a disclosed embodiment of a curing temperature profilefor concrete in accordance with the present invention. An example ofambient temperature is also shown on the graph.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS

Referring now to the drawing in which like numbers indicate likeelements throughout the several views, there is shown in FIG. 1 atypical prior art concrete form 10. The concrete form 10 comprises arectangular concrete forming face panel 12 made of a wood materialtypically used in prior art concrete forms. Most prior art concreteforms use wood, plywood, wood composite materials, or wood or compositematerials with polymer coatings for the concrete forming panel of theirconcrete forms. A preferred prior art material for the face panel 12 isa sheet of high density overlay (HDO) plywood. The prior art face panel12 can be any useful thickness depending on the anticipated load theform will be subjected to. However, thicknesses of 0.5 inches to ⅞inches are typically used. The panel 12 has a first primary surface 14for contacting plastic concrete and an opposite second primary surface16. The first surface 14 is usually smooth and flat. However, the firstsurface 14 can also be contoured so as to form a desired design in theconcrete, such as a brick or stone pattern. The first surface 14 canalso include a polymer coating to make the surface smoother, moredurable and/or provide better release properties.

Attached to the second surface 16 of the panel 12 is a rectangular frame18, which comprises two elongate longitudinal members 20, 22 and twoelongate transverse members 24, 26. The longitudinal members 20, 22 andthe transverse members 24, 26 are attached to each other and to the facepanel 12 by any suitable means used in the prior art. The frame 18 alsocomprises at least one, and preferably a plurality, of transversebracing members 28, 30, 32, 34, 36, 36, 40, 42, 44. The transversebracing members 28-44 are attached to the longitudinal members 20, 22and to the panel 12 by any suitable means used in the prior art. Theframe 18 also includes bracing members 48, 50 and 52, 54. The bracingmembers 48, 50 extend between the transverse member 26 and the bracingmember 28. The bracing members 48, 50 are attached to the transversemember 26 and the bracing member 28 and to the panel 12 by any suitablemeans used in the prior art. The bracing members 52, 54 extend betweenthe transverse member 24 and the bracing member 44. The bracing members52, 54 are attached to the transverse member 24 and the bracing member44 and to the panel 12 by any suitable means used in the prior art. Theframe 18 helps prevent the panel 12 from flexing or deforming under thehydrostatic pressure of the plastic concrete when place between opposedforms. The frame 18 can be made from any suitable material, such as woodor metal, such as aluminum or steel, depending on the load to which theform will be subjected. The particular design of the frame 18 is notcritical to the present invention. There are many different designs offrames for concrete forms and they are all applicable to the presentinvention.

The present invention departs from conventional prior art plywood-typeconcrete forms, such as the form 10, as explained below. With referenceto FIGS. 4-6 there is shown a composite insulated concrete form 100 inaccordance with the present invention. The concrete form 100 comprises aface or first panel 110 and a frame 112. The first panel 110 and frame112 can be identical to the prior art face panel 12 and frame 18, asdescribed above, and therefore will not be described in any more detailhere. The first panel 110 has a first primary surface 114 for contactingplastic concrete and an opposite second primary surface 116. The firstpanel 110 defines a plane. The insulated concrete form 100 alsocomprises a second panel 118 identical, or substantially identical, tothe first panel 110. The second panel 118 has a first primary surface120 and an opposite second primary surface 122. The first primarysurface 120 of the second panel 118 is adjacent the second primarysurface 116 of the first panel 110. Disposed between the first andsecond panels 110, 118 is a layer of insulating material 124. The layerof insulating material 124 covers, or substantially covers, the secondprimary surface 116 of the first panel 110 and the first primary surface120 of the second panel 118. As used herein the term “substantiallycovers” means covering at least 80% of the surface area of the secondprimary surface 116 of the first panel 110.

For the insulated concrete form 100, the layer of insulating material124 is made from any suitable material providing conductive heatinsulating properties, preferably a sheet of closed cell polymeric foam.The layer of insulating material 124 is preferably made from closed cellfoams of polyvinyl chloride, urethane, polyurethane, polyisocyanurate,phenol, polyethylene, polyimide or polystyrene. Such foam preferably hasa density of 1 to 3 pounds per cubic foot, or more. The layer ofinsulating material 124 preferably has insulating properties equivalentto at least 0.25 inches of expanded polystyrene foam, equivalent to atleast 0.5 inches of expanded polystyrene foam, preferably equivalent toat least 1 inch of expanded polystyrene foam, more preferably equivalentto at least 2 inches of expanded polystyrene foam, more preferablyequivalent to at least 3 inches of expanded polystyrene foam, mostpreferably equivalent to at least 4 inches of expanded polystyrene foam.There is no maximum thickness for the equivalent expanded polystyrenefoam useful in the present invention. The maximum thickness is usuallydictated by economics, ease of handling and building or structuredesign. However, for most applications a maximum insulating equivalenceof 8 inches of expanded polystyrene foam can be used. In anotherembodiment of the present invention, the layer of insulating material202 has insulating properties equivalent to approximately 0.25 toapproximately 8 inches of expanded polystyrene foam, preferablyapproximately 0.5 to approximately 8 inches of expanded polystyrenefoam, preferably approximately 1 to approximately 8 inches of expandedpolystyrene foam, preferably approximately 2 to approximately 8 inchesof expanded polystyrene foam, more preferably approximately 3 toapproximately 8 inches of expanded polystyrene foam, most preferablyapproximately 4 to approximately 8 inches of expanded polystyrene foam.These ranges for the equivalent insulating properties include all of theintermediate values. Thus, the layer of insulating material 124 used inanother disclosed embodiment of the present invention has insulatingproperties equivalent to approximately 0.25 inches of expandedpolystyrene foam, approximately 0.5 inches of expanded polystyrene foam,approximately 1 inch of expanded polystyrene foam, approximately 2inches of expanded polystyrene foam, approximately 3 inches of expandedpolystyrene foam, approximately 4 inches of expanded polystyrene foam,approximately 5 inches of expanded polystyrene foam, approximately 6inches of expanded polystyrene foam, approximately 7 inches of expandedpolystyrene foam, or approximately 8 inches of expanded polystyrenefoam. Expanded polystyrene foam has an R-value of approximately 4 to 5per inch thickness. Therefore, the layer of insulating material 124should have an R-value of greater than 1.5, preferably greater than 4,more preferably greater than 8, especially greater than 12, mostespecially greater than 20. The layer of insulating material 124preferably has an R-value of approximately 1.5 to approximately 40; morepreferably between approximately 4 to approximately 40; especiallyapproximately 8 to approximately 40; more especially approximately 12 toapproximately 40. The layer of insulating material 124 preferably has anR-value of approximately 1.5, more preferably approximately 4, mostpreferably approximately 8, especially approximately 20, more especiallyapproximately 30, most especially approximately 40.

The layer of insulating material 124 can also be made from a refractoryinsulating material, such as a refractory blanket, a refractory board ora refractory felt or paper. Refractory insulation is typically used toline high temperature furnaces or to insulate high temperature pipes.Refractory insulating material is typically made from ceramic fibersmade from materials including, but not limited to, silica, siliconcarbide, alumina, aluminum silicate, aluminum oxide, zirconia, calciumsilicate; glass fibers, mineral wool fibers, Wollastonite and fireclay.Refractory insulating material is commercially available in various formincluding, but not limited to, bulk fiber, foam, blanket, board, feltand paper form. Refractory insulation is commercially available inblanket form as Fiberfrax Durablanket® insulation blanket from Unifrax ILLC, Niagara Falls, N.Y., USA and RSI4-Blank and RSI8-Blank fromRefractory Specialties Incorporated, Sebring, Ohio, USA. Refractoryinsulation is commercially available in board form as Duraboard® fromUnifrax I LLC, Niagara Falls, N.Y., USA and CS85, Marinite and Transiteboards from BNZ Materials Inc., Littleton, Colo., USA. Refractoryinsulation in felt form is commercially available as Fibrax Felts andFibrax Papers from Unifrax I LLC, Niagara Falls. The refractoryinsulating material can be any thickness that provides the desiredinsulating properties, as set forth above. There is no upper limit onthe thickness of the refractory insulating material; this is usuallydictated by economics. However, refractory insulating material useful inthe present invention can range from 1/32 inch to approximately 2inches. Similarly, ceramic fiber materials including, but not limitedto, silica, silicon carbide, alumina, aluminum silicate, aluminum oxide,zirconia, calcium silicate; glass fibers, mineral wool fibers,Wollastonite and fireclay, can be suspended in a polymer or polymericfoam, such as polyurethane, latex, cement or epoxy, and used as acoating or a polymeric foam to create a refractory insulating materiallayer, for example covering, or substantially covering, one of theprimary surfaces 116, 120 of the first or second panels 110, 118, orboth. Such a refractory insulating material layer can be used as thelayer of insulating material 124 to block excessive ambient heat loadsand retain the heat of hydration within the insulated concrete forms ofthe present invention. Ceramic fibers suspended in a polymer binder,such as latex or latex foam, are commercially available as Super Therm®,Epoxotherm and HPC Coating from Superior Products, II, Inc., Weston,Fla., USA. Fillers can also be added to the polymer or polymeric foam,such as fly ash, volcanic ash, crushed glass, glass spheres and thelike.

The layer of insulating material 124 is preferably a multi-layermaterial with a first layer of refractory insulating material and asecond layer of polymeric foam insulating material. The layer ofinsulating material 124 more preferably comprises a layer of refractoryinsulating felt or board and a layer of expanded polystyrene foam. Thelayer of insulating material 124 more preferably comprises a layer ofrefractory insulating material, such as a felt or board, and a layer ofexpanded polystyrene foam. Alternatively, the layer of insulatingmaterial 124 comprises a layer of expanded polystyrene, a layer ofradiant heat reflective material, such as a metal foil, especiallyaluminum foil, and second layer of expanded polystyrene foam to form asandwich with the radiant heat reflective material in the middle. Inanother disclosed embodiment, the layer of insulating material 124comprises a layer of refractory material, a layer of radiant heatreflective material, such as a metal foil, especially aluminum foil, anda layer of expanded polystyrene foam to form a sandwich with the radiantheat reflective material in the middle. In still another disclosedembodiment, the layer of insulating material 124 comprises a layer ofrefractory material, a layer of radiant heat reflective material, suchas a metal foil, especially aluminum foil, and a second layer ofrefractory material to form a sandwich with the radiant heat reflectivematerial in the middle.

The first and second panels 116, 120 are preferably made from rigidsheets of plastic or metal. The first and second panels 116, 120 arepreferably made from the same material. However, it is also contemplatedthat one of the first or second panels 116, 120 can be made from plasticand the other made from metal. Suitable metals include, but are notlimited to, steel and aluminum. Suitable plastics include, but are notlimited to, polyethylene (PE), poly(ethylene terephthalate) (PET),polypropylene (PP), polyvinyl chloride (PVC), chlorinated polyvinylchloride (CPVC), acrylonitrile butadiene styrene (ABS), polycarbonate,polystyrene, nylon, urethane, polyurethane (PU), polyisocyanurate,phenol, polyimide, acrylic polymers such as polyacrylate, poly(methylmethacrylate) (PMMA), and the like. Alternatively, the first panel 116can be made from rigid sheets of plastic or metal and the second panel120 can be made from wood or plywood.

A particularly preferred plastic sheet for use as the first and/orsecond panels 116, 120 is corrugated plastic. Corrugated plastic sheettypically comprises two planar plastic sheet spaced from each other butconnected to each other by a plurality of small I-beam formed plastic.The I-beam formed plastic connections between the planar sheets ofplastic can be either perpendicular to the planar sheets of plastic orslanted. Corrugated plastic sheets can also be made by sandwiching afluted sheet of plastic between two flat sheets of plastic (also calledfacings). The sheets can be joined together by gluing. The corrugatedplastic sheet can be single wall corrugated sheets, double wallcorrugated sheets or triple wall corrugated sheets. The insulatingmaterial 124 can then be applied to one or both of the corrugated sheetthat form the first and second panels 116, 120 or the insulatingmaterial can be adhered to one or both of the corrugated sheets.

In another disclosed embodiment, if the corrugations of a corrugatedplastic sheet are large enough; e.g., approximately 0.5 inches betweenthe facings, the two facings of the corrugated sheet can be use as thefirst and second panels 116, 120. The insulating material 124 thenpreferably can be injected between the two facings and between thecorrugations. In this case, the insulating material 124 is preferablyfoamed liquid plastic or a liquid plastic that blows in situ to form afoam. The foamed liquid plastic or a liquid plastic that blows in situis then allowed to set and cure inside the corrugated plastic sheet.

In another disclosed embodiment a first plastic sheet can be laid on awork surface. A layer of plastic foam or a layer of liquid plastic thatblows in situ can then be deposited on the first plastic sheet. A secondplastic sheet can then be disposed on the layer of plastic foam or alayer of liquid plastic that blows in situ. Before the layer of plasticfoam or a layer of liquid plastic that blows in situ, the first andsecond plastic sheets can be gauged to a desired thickness, such as bypassing the first and second plastic sheets between a pair of spacedgauge rollers. After the first and second plastic sheets have beengauged to a desired thickness, the layer of plastic foam or a layer ofliquid plastic that blows in situ is allowed to cure. If necessary, thesandwich of the first and second plastic sheets with the layer ofplastic foam in between can be cut to a desired size and shape.

In another disclosed embodiment a first metal sheet can be laid on awork surface. A layer of plastic foam or a layer of liquid plastic thatblows in situ can then be deposited on the first metal sheet. A secondsheet of plastic or other composite insulating material can then bedisposed on the layer of plastic foam or a layer of liquid plastic thatblows in situ. Before the layer of plastic foam or a layer of liquidplastic that blows in situ sets up, the first and second sheets can begauged to a desired thickness, such as by passing the first and secondsheets between a pair of spaced gauge rollers. After the first andsecond sheets have been gauged to a desired thickness, the layer ofplastic foam or a layer of liquid plastic that blows in situ is allowedto cure. If necessary, the sandwich of the first and second sheets withthe layer of plastic foam in between can be cut to a desired size andshape. Any of the foregoing foams can have ceramic fibers suspendedtherein, so as to create a better conductive heat insulating and radiantheat reflective material.

Use of the insulated concrete form 100 will now be considered. Theinsulated concrete form 100 attached to either a wood or metal frame canbe used in the same way as a conventional prior art plywood-type form,such as the concrete form 10. Two identical removable insulated concreteforms 100 are placed vertically and horizontally spaced from each other,in a manner well known in the art. Typically, multiple forms areattached to each other linearly to form, for example a wall of a desiredlength and configuration. Then, plastic concrete is placed in the spaceddefined by the two opposed insulated concrete forms 100. The removableinsulated concrete forms 100 are left in place for a time sufficient forthe plastic concrete within the form to at least partially cure. Whilethe insulated concrete forms 100 are in place, the layer of radiant heatreflective material 124 reduces the amount of heat of hydration lostfrom the curing concrete by reflecting at least some of the radiant heattherefrom back into the concrete. By retaining a portion of the heat ofhydration, the plastic concrete in the insulated concrete form 100 curesmore quickly and achieve better physical properties than it would havehad it been cured in a conventional plywood-type concrete form, such asthe concrete form 10. This is true for conventional portland cementconcrete, but is even more so for concrete including slag cement and/orfly ash or other pozzolanic materials, as described below. Furthermore,it is desirable to leave the insulated concrete forms 100 in place withthe curing concrete there between for a period of 1 to 28 days,preferably 1 to 14 days, more preferably 2 to 14 days, especially 5 to14 days, more especially 1 to 7 days, most especially 1 to 3 days. Afterthe concrete has cured to a desired degree, the insulated concrete forms100 can be stripped from the concrete in a conventional manner known inthe art. At this point, the concrete has relatively high strength andtherefore can better withstand stresses associated with temperaturechanges.

The insulated concrete form 100 of the present invention is advantageousover the prior art because it can be used in the same manner as a priorart plywood-type frame concrete form. Therefore, there is no newtraining required to install or remove these forms. However, theinsulated concrete form 100 produces cured concrete more quickly andconcrete having improved physical properties without adding expensivechemical additives and without adding energy to the curing concrete. Theinsulated concrete form 100 also provides the option of reducing theamount of portland cement in the concrete mix, and, therefore, reducingthe cost thereof and improving concrete performance.

FIGS. 7 and 8 show an alternate disclosed embodiment of the presentinvention in the form of an insulated precast concrete horizontalcasting table 200. The horizontal casting table 200 comprises arectangular frame including outer side members 244, 246, 248, 250. Theouter side members 244, 246, 248, 250 are preferably made from anconductive heat insulating material or a material having relatively poorheat conducting properties, including, but not limited to, wood,plywood, wood composite materials, non-metal composite materials orinsulating plastic. The horizontal casting table 200 further comprises asupport frame including four horizontal transverse frame members 202,204, 206, 208 preferably made from a strong material, such as steel oraluminum. The support frame also includes two horizontal longitudinalframe members 210, 212. The frame members 202, 204, 206, 208 are jointedto the frame members 210, 212 is a conventional manner. Attached to theframe members 202-212 is a horizontal first plate member 214. The firstplate member 214 is made from a strong, rigid material including, butnot limited to, wood, plastic, composite materials, steel and aluminum.Disposed above the first plate member 214 and spaced therefrom is anidentical horizontal second plate member 216. Disposed between the firstand second plate members 214, 216 is a layer of insulating material 218.The layer of insulating material covers, or substantially covers, thesurface of the first and second plate members 214, 216. Disposed on thesecond plate member 216 at the peripheral edges thereof are first sidemembers 220, 222, 224, 226. Disposed on the second plate members andspaced from the first side members 220-226 are second side members 228,230, 232, 234. Disposed between the first side members 220-226 and thesecond side members 228-234 are layers of insulating material 236, 238,240, 242. The layers of insulating material 236-242 cover, orsubstantially cover, the surface of the first side members 220-226,respectively, and the surface of the second side members 228-234,respectively.

For the insulated precast concrete horizontal casting table 200, thelayers of insulating material 218, 236-242 are made from any suitablematerial providing conductive heat insulating properties, preferablysheets of closed cell polymeric foam. The layers of insulating material218, 236-242 are preferably made from closed cell foams of polyvinylchloride, urethane, polyurethane, polyisocyanurate, phenol,polyethylene, polyimide or polystyrene. Such foam preferably has adensity of 1 to 3 pounds per cubic foot, or more. The layers ofinsulating material 218, 236-242 preferably have insulating propertiesequivalent to at least 0.25 inches of expanded polystyrene foam,equivalent to at least 0.5 inches of expanded polystyrene foam,preferably equivalent to at least 1 inch of expanded polystyrene foam,more preferably equivalent to at least 2 inches of expanded polystyrenefoam, more preferably equivalent to at least 3 inches of expandedpolystyrene foam, most preferably equivalent to at least 4 inches ofexpanded polystyrene foam. There is no maximum thickness for theequivalent expanded polystyrene foam useful in the present invention.The maximum thickness is usually dictated by economics, ease of handlingand building or structure design. However, for most applications amaximum insulating equivalence of 8 inches of expanded polystyrene foamcan be used. In another embodiment of the present invention, the layersof insulating material 218, 236-242 have insulating propertiesequivalent to approximately 0.25 to approximately 8 inches of expandedpolystyrene foam, preferably approximately 0.5 to approximately 8 inchesof expanded polystyrene foam, preferably approximately 1 toapproximately 8 inches of expanded polystyrene foam, preferablyapproximately 2 to approximately 8 inches of expanded polystyrene foam,more preferably approximately 3 to approximately 8 inches of expandedpolystyrene foam, most preferably approximately 4 to approximately 8inches of expanded polystyrene foam. These ranges for the equivalentinsulating properties include all of the intermediate values. Thus, thelayers of insulating material 218, 236-242 used in another disclosedembodiment of the present invention have insulating propertiesequivalent to approximately 0.25 inches of expanded polystyrene foam,approximately 0.5 inches of expanded polystyrene foam, approximately 1inch of expanded polystyrene foam, approximately 2 inches of expandedpolystyrene foam, approximately 3 inches of expanded polystyrene foam,approximately 4 inches of expanded polystyrene foam, approximately 5inches of expanded polystyrene foam, approximately 6 inches of expandedpolystyrene foam, approximately 7 inches of expanded polystyrene foam,or approximately 8 inches of expanded polystyrene foam. Expandedpolystyrene foam has an R-value of approximately 4 to 5 per inchthickness. Therefore, the layers of insulating material 218, 236-242should have an R-value of greater than 1.5, preferably greater than 4,more preferably greater than 8, especially greater than 12, mostespecially greater than 20. The layer of insulating material 124preferably has an R-value of approximately 1.5 to approximately 40; morepreferably between approximately 4 to approximately 40; especiallyapproximately 8 to approximately 40; more especially approximately 12 toapproximately 40. The layers of insulating material 218, 236-242preferably have an R-value of approximately 1.5, more preferablyapproximately 4, most preferably approximately 8, especiallyapproximately 20, more especially approximately 30, most especiallyapproximately 40.

The layers of insulating material 218, 236-242 can also be made from arefractory insulating material, such as a refractory blanket, arefractory board or a refractory felt or paper. Refractory insulation istypically used to line high temperature furnaces or to insulate hightemperature pipes. Refractory insulating material is typically made fromceramic fibers made from materials including, but not limited to,silica, silicon carbide, alumina, aluminum silicate, aluminum oxide,zirconia, calcium silicate; glass fibers, mineral wool fibers,Wollastonite and fireclay. Refractory insulating material iscommercially available in various form including, but not limited to,bulk fiber, foam, blanket, board, felt and paper form. Refractoryinsulation is commercially available in blanket form as FiberfraxDurablanket® insulation blanket from Unifrax I LLC, Niagara Falls, N.Y.,USA and RSI4-Blank and RSI8-Blank from Refractory SpecialtiesIncorporated, Sebring, Ohio, USA. Refractory insulation is commerciallyavailable in board form as Duraboard® from Unifrax I LLC, Niagara Falls,N.Y., USA and CS85, Marinite and Transite boards from BNZ MaterialsInc., Littleton, Colo., USA. Refractory insulation in felt form iscommercially available as Fibrax Felts and Fibrax Papers from Unifrax ILLC, Niagara Falls. The refractory insulating material can be anythickness that provides the desired insulating properties, as set forthabove. There is no upper limit on the thickness of the refractoryinsulating material; this is usually dictated by economics. However,refractory insulating material useful in the present invention can rangefrom 1/32 inch to approximately 2 inches. Similarly, ceramic fibermaterials including, but not limited to, silica, silicon carbide,alumina, aluminum silicate, aluminum oxide, zirconia, calcium silicate;glass fibers, mineral wool fibers, Wollastonite and fireclay, can besuspended in a polymer or polymeric foam, such as polyurethane, latex,cement or epoxy, and used as a coating or a polymeric foam to create arefractory insulating material layer, for example covering, orsubstantially covering, one of the primary surfaces first plate member214 or the second plate member 216, or both and covering, orsubstantially covering, a primary surface of the first side members220-226 or the second side members 228-234 or both. Such a refractoryinsulating material layer can be used as the layers of insulatingmaterial 218, 236-242 to block excessive ambient heat loads and retainthe heat of hydration within the insulated concrete forms of the presentinvention. Ceramic fibers suspended in a polymer binder, such as latexor latex foam, are commercially available as Super Therm®, Epoxothermand HPC Coating from Superior Products, II, Inc., Weston, Fla., USA.Fillers can also be added to the polymer or polymeric foam, such as flyash, volcanic ash, crushed glass, glass spheres and the like.

The layers of insulating material 218, 236-242 are preferably amulti-layer material with a first layer of refractory insulatingmaterial and a second layer of polymeric foam insulating material. Thelayers of insulating material 218, 236-242 more preferably comprise alayer of refractory insulating felt or board and a layer of expandedpolystyrene foam. The layers of insulating material 218, 236-242 morepreferably comprise a layer of refractory insulating material, such as afelt or board, and a layer of expanded polystyrene foam. Alternatively,the layers of insulating material 218, 236-242 comprise a layer ofexpanded polystyrene, a layer of radiant heat reflective material, suchas a metal foil, especially aluminum foil, and second layer of expandedpolystyrene foam to form a sandwich with the radiant heat reflectivematerial in the middle. In another disclosed embodiment, the layers ofinsulating material 218, 236-242 comprise a layer of refractorymaterial, a layer of radiant heat reflective material, such as a metalfoil, especially aluminum foil, and a layer of expanded polystyrene foamto form a sandwich with the radiant heat reflective material in themiddle. In still another disclosed embodiment, the layers of insulatingmaterial 218, 236-242 comprise a layer of refractory material, a layerof radiant heat reflective material, such as a metal foil, especiallyaluminum foil, and a second layer of refractory material to form asandwich with the radiant heat reflective material in the middle.

Use of the insulated precast casting table 200 will now be considered.The second plate member 216 and the four second side members 228-234define a mold or concrete receiving space for receiving plasticconcrete. Plastic concrete 240 is placed on top of the second platemember 216 and until the concrete reaches a desired thickness. Thesecond side members 228-234 define the sides of the mold and form theedges of the concrete 240. After the plastic concrete 240 is placed inthe precast mold and the surface of the concrete is finished, asdesired, a layer of insulating material 242 is placed on top of thefirst side members 220-226 and the second side members 228-234.

The layer of insulating material 242 is left on the insulated precastcasting table 200 for a time sufficient for the concrete panels toachieve a desired amount or degree of cure. The amount of time for theconcrete panels to reach a desired amount or degree of cure will varybased on a number of factors including the concrete mix design, the sizeof the concrete panels, the concrete panels temperature at the time ofremoval from the battery mold, ambient temperature conditions, theamount of insulation provided around the stacked concrete panels, theamount and kind of concrete curing additives used and the like. However,the concrete panels will usually achieve a sufficient amount or degreeof cure within 1 to approximately 14 days, preferably 1 to approximately10 days, more preferably 1 to approximately 7 days, most preferably 1 toapproximately 5 days, especially 1 to approximately 3 days, moreespecially approximately 12 hours to approximately 3 days. After theconcrete panels have achieved a desired amount or degree of cure, thelayer of insulating material 242 is removed and the concrete panels areremoved from the mold.

In an alternate disclosed embodiment, the layer of insulating material242 is an electrically heated concrete curing blanket. When anelectrically heated concrete curing blanket is used for the layer ofinsulating material 242, heat can be applied to the plastic concretewithin the mold to accelerate the curing of the plastic concrete.

In another disclosed embodiment of the present invention, when anelectrically heated concrete curing blanket is used for the layer ofinsulating material 242, it is desirable for the temperature of theconcrete within the mold to be controlled so that the temperature of theconcrete follows a predetermined temperature profile in the mannerdisclosed in applicant's U.S. Pat. No. 8,532,815 (the disclosure ofwhich is incorporated herein by reference in its entirety). To do so,the electrically heat concrete curing blanket is controlled by acontroller connected to a computing device that is also connected to oneor more temperature sensors configured to sense the temperature of theconcrete in the mold in the same manner as disclosed in applicant's U.S.Pat. No. 8,532,815 (the disclosure of which is incorporated herein byreference in its entirety).

FIGS. 9 and 10 show an alternate disclosed embodiment of the presentinvention in the form of an insulated precast concrete horizontalcasting table 300. The horizontal casting table 300 comprises arectangular frame including outer side members 302, 304, 306, 308. Thehorizontal casting table 300 further comprises a support frame includingfour horizontal transverse frame members 310, 312, 314, 316 preferablymade from a strong material, such as steel or aluminum. The supportframe also includes two horizontal longitudinal frame members 318, 320.The frame members 310-316 are jointed to the frame members 210, 212 in aconventional manner. Attached to the frame members 310-320 is ahorizontal first plate member 322. The first plate member 322 is madefrom a strong, rigid material including, but not limited to, wood,plastic, composite materials, steel or aluminum. Disposed above thefirst plate member 322 and spaced therefrom is an identical horizontalsecond plate member 324. Disposed between the first and second platemembers 322, 324 is a layer of insulating material 326. The layer ofinsulating material 326 covers, or substantially covers, the surface ofthe first and second plate members 322, 324. Disposed on the secondplate member 324 at the peripheral edges thereof are first side members328, 330, 332, 334. Joined to the second plate member 324 and spacedfrom the first side members 328-334 are second side members 336, 338,340, 342. Disposed between the first side members 328-334 and the secondside members 336-342 are layers of insulating material 344, 346, 348,350. The layers of insulating material 344-350 cover, or substantiallycover, the surface of the first side members 328-334, respectively, andthe surface of the second side members 336-342, respectively. The layerof insulating material 326 and the layers of insulating material 344-350for a continuous layer of insulation on the second plate 324 and secondside members 336-342. This effectively thermally isolates the secondplate 324 and second side members 336-342 from the environment and thereis no thermal bridging of the second plate and second side members toother members in contact with the surrounding environment.

For the insulated precast concrete horizontal casting table 300, thelayers of insulating material 324, 336-342 are made from any suitablematerial providing conductive heat insulating properties, preferablyclosed cell polymeric foam. The layers of insulating material 324,336-342 are preferably made from closed cell foams of polyvinylchloride, urethane, polyurethane, polyisocyanurate, phenol,polyethylene, polyimide or polystyrene. Such foam preferably has adensity of 1 to 3 pounds per cubic foot, or more. The layers ofinsulating material 324, 336-342 preferably have insulating propertiesequivalent to at least 0.25 inches of expanded polystyrene foam,equivalent to at least 0.5 inches of expanded polystyrene foam,preferably equivalent to at least 1 inch of expanded polystyrene foam,more preferably equivalent to at least 2 inches of expanded polystyrenefoam, more preferably equivalent to at least 3 inches of expandedpolystyrene foam, most preferably equivalent to at least 4 inches ofexpanded polystyrene foam. There is no maximum thickness for theequivalent expanded polystyrene foam useful in the present invention.The maximum thickness is usually dictated by economics, ease of handlingand building or structure design. However, for most applications amaximum insulating equivalence of 8 inches of expanded polystyrene foamcan be used. In another embodiment of the present invention, the layersof insulating material 324, 336-342 have insulating propertiesequivalent to approximately 0.25 to approximately 8 inches of expandedpolystyrene foam, preferably approximately 0.5 to approximately 8 inchesof expanded polystyrene foam, preferably approximately 1 toapproximately 8 inches of expanded polystyrene foam, preferablyapproximately 2 to approximately 8 inches of expanded polystyrene foam,more preferably approximately 3 to approximately 8 inches of expandedpolystyrene foam, most preferably approximately 4 to approximately 8inches of expanded polystyrene foam. These ranges for the equivalentinsulating properties include all of the intermediate values. Thus, thelayers of insulating material 324, 336-342 used in another disclosedembodiment of the present invention have insulating propertiesequivalent to approximately 0.25 inches of expanded polystyrene foam,approximately 0.5 inches of expanded polystyrene foam, approximately 1inch of expanded polystyrene foam, approximately 2 inches of expandedpolystyrene foam, approximately 3 inches of expanded polystyrene foam,approximately 4 inches of expanded polystyrene foam, approximately 5inches of expanded polystyrene foam, approximately 6 inches of expandedpolystyrene foam, approximately 7 inches of expanded polystyrene foam,or approximately 8 inches of expanded polystyrene foam. Expandedpolystyrene foam has an R-value of approximately 4 to 5 per inchthickness. Therefore, the layers of insulating material 324, 336-342should have an R-value of greater than 1.5, preferably greater than 4,more preferably greater than 8, especially greater than 12, mostespecially greater than 20. The layer of insulating material 124preferably has an R-value of approximately 1.5 to approximately 40; morepreferably between approximately 4 to approximately 40; especiallyapproximately 8 to approximately 40; more especially approximately 12 toapproximately 40. The layers of insulating material 324, 336-342preferably have an R-value of approximately 1.5, more preferablyapproximately 4, most preferably approximately 8, especiallyapproximately 20, more especially approximately 30, most especiallyapproximately 40.

The layers of insulating material 324, 336-342 can also be made from arefractory insulating material, such as a refractory blanket, arefractory board or a refractory felt or paper. Refractory insulation istypically used to line high temperature furnaces or to insulate hightemperature pipes. Refractory insulating material is typically made fromceramic fibers made from materials including, but not limited to,silica, silicon carbide, alumina, aluminum silicate, aluminum oxide,zirconia, calcium silicate; glass fibers, mineral wool fibers,Wollastonite and fireclay. Refractory insulating material iscommercially available in various form including, but not limited to,bulk fiber, foam, blanket, board, felt and paper form. Refractoryinsulation is commercially available in blanket form as FiberfraxDurablanket® insulation blanket from Unifrax I LLC, Niagara Falls, N.Y.,USA and RSI4-Blank and RSI8-Blank from Refractory SpecialtiesIncorporated, Sebring, Ohio, USA. Refractory insulation is commerciallyavailable in board form as Duraboard® from Unifrax I LLC, Niagara Falls,N.Y., USA and CS85, Marinite and Transite boards from BNZ MaterialsInc., Littleton, Colo., USA. Refractory insulation in felt form iscommercially available as Fibrax Felts and Fibrax Papers from Unifrax ILLC, Niagara Falls. The refractory insulating material can be anythickness that provides the desired insulating properties, as set forthabove. There is no upper limit on the thickness of the refractoryinsulating material; this is usually dictated by economics. However,refractory insulating material useful in the present invention can rangefrom 1/32 inch to approximately 2 inches. Similarly, ceramic fibermaterials including, but not limited to, silica, silicon carbide,alumina, aluminum silicate, aluminum oxide, zirconia, calcium silicate;glass fibers, mineral wool fibers, Wollastonite and fireclay, can besuspended in a polymer or polymeric foam, such as polyurethane, latex,cement or epoxy, and used as a coating or a polymeric foam to create arefractory insulating material layer, for example covering, orsubstantially covering, one of the primary surfaces first plate member322 or the second plate member 324, or both and covering, orsubstantially covering, a primary surface of the first side members328-334 or the second side members 336-342 or both. Such a refractoryinsulating material layer can be used as the layers of insulatingmaterial 324, 336-342 to block excessive ambient heat loads and retainthe heat of hydration within the insulated concrete forms of the presentinvention. Ceramic fibers suspended in a polymer binder, such as latexor latex foam, are commercially available as Super Therm®, Epoxothermand HPC Coating from Superior Products, II, Inc., Weston, Fla., USA.Fillers can also be added to the polymer or polymeric foam, such as flyash, volcanic ash, crushed glass, glass spheres and the like.

The layers of insulating material 324, 336-342 are preferably amulti-layer material with a first layer of refractory insulatingmaterial and a second layer of polymeric foam insulating material. Thelayers of insulating material 324, 336-342 more preferably comprise alayer of refractory insulating material, such as a felt or board, and alayer of expanded polystyrene foam. Alternatively, the layers ofinsulating material 324, 336-342 comprise a layer of expandedpolystyrene, a layer of radiant heat reflective material, such as ametal foil, especially aluminum foil, and second layer of expandedpolystyrene foam to form a sandwich with the radiant heat reflectivematerial in the middle. In another disclosed embodiment, the layers ofinsulating material 324, 336-342 comprise a layer of refractorymaterial, a layer of radiant heat reflective material, such as a metalfoil, especially aluminum foil, and a layer of expanded polystyrene foamto form a sandwich with the radiant heat reflective material in themiddle. In still another disclosed embodiment, the layers of insulatingmaterial 324, 336-342 comprise a layer of refractory material, a layerof radiant heat reflective material, such as a metal foil, especiallyaluminum foil, and a second layer of refractory material to form asandwich with the radiant heat reflective material in the middle.

Use of the insulated precast casting table 300 will now be considered.The second plate member 324 and the four second side members 336-342define a mold or concrete receiving space for receiving plasticconcrete. Plastic concrete 360 is placed on top of the second platemember 324 and until the concrete reaches a desired thickness. Thesecond side members 336-342 define the sides of the mold and form theedges of the concrete 360. After the plastic concrete 360 is placed inthe precast mold and the surface of the concrete is finished, asdesired, a layer of insulating material 362 is placed on top of thefirst side members 328-334 and the second side members 336-342.

The layer of insulating material 362 is left on the insulated precastcasting table 300 for a time sufficient for the concrete panels toachieve a desired amount or degree of cure. The amount of time for theconcrete panels to reach a desired amount or degree of cure will varybased on a number of factors including the concrete mix design, the sizeof the concrete panels, the concrete panels temperature at the time ofremoval from the battery mold, ambient temperature conditions, theamount of insulation provided around the stacked concrete panels, theamount and kind of concrete curing additives used and the like. However,the concrete panels will usually achieve a sufficient amount or degreeof cure within 1 to approximately 14 days, preferably 1 to approximately10 days, more preferably 1 to approximately 7 days, most preferably 1 toapproximately 5 days, especially 1 to approximately 3 days, moreespecially approximately 12 hours to approximately 3 days. After theconcrete panels have achieved a desired amount or degree of cure, thelayer of insulating material 362 is removed and the concrete panels areremoved from the mold.

In an alternate disclosed embodiment, the layer of insulating material362 is an electrically heated concrete curing blanket. When anelectrically heated concrete curing blanket is used for the layer ofinsulating material 362, heat can be applied to the plastic concretewithin the mold to accelerate the curing of the plastic concrete.

In another disclosed embodiment of the present invention, when anelectrically heated concrete curing blanket is used for the layer ofinsulating material 362, it is desirable for the temperature of theconcrete within the mold to be controlled so that the temperature of theconcrete follows a predetermined temperature profile in the mannerdisclosed in applicant's U.S. Pat. No. 8,532,815 (the disclosure ofwhich is incorporated herein by reference in its entirety). To do so,the electrically heat concrete curing blanket is controlled by acontroller connected to a computing device that is also connected to oneor more temperature sensors configured to sense the temperature of theconcrete 362 in the mold in the same manner as disclosed in applicant'sU.S. Pat. No. 8,532,815 (the disclosure of which is incorporated hereinby reference in its entirety).

FIG. 11 shows a graph of a disclosed embodiment of a desired curingtemperature profile for concrete as a function of time in accordancewith the present invention. In this graph, the temperature of theconcrete is shown on the vertical axis and elapsed concrete curing timeis shown on the horizontal axis. The intersection of the vertical andhorizontal axes represents 0° C. concrete temperature and zero elapsedconcrete curing time. Ambient temperature is also shown on this graph.The peaks and troughs of the ambient temperature represent the daily(i.e., day to night) fluctuation of ambient temperature. As can be seenin this graph, the temperature of the concrete initially increases quiterapidly over a relatively short time, such as 1 to 3 days. After aperiod of time, the concrete temperature reaches a maximum and thenslowly drops to ambient temperature over an extended period, such as 1to 7 days, preferably 1 to 14 days, more preferably 1 to 28 days,especially 3 to 5 days or more especially 5 to 7 days. The maximumtemperature will vary depending on the composition of the concrete mix.However, it is desirable that the maximum temperature is at least 35°C., preferably, at least 40° C., at least 45° C., at least 50° C., atleast 55° C., at least 60° C. or at least 65° C. The maximum concretetemperature should not exceed about 70° C. The maximum concretetemperature is preferably about 70° C., about 69° C., about 68° C.,about 67° C., about 66° C., about 65° C., about 64° C., about 63° C.,about 62° C., about 61° C. about 60° C. or about 60 to about 70° C.Furthermore, it is desirable that the temperature of the concrete ismaintained above approximately 30° C., approximately 35° C.,approximately 40° C., approximately 45° C., approximately 50° C.,approximately 55° C. or approximately 60° C. for 1 to approximately 4days from the time of concrete placement, preferably 1 to approximately3 days from the time of concrete placement, more preferably about 24 toabout 48 hours from the time of concrete placement. It is also desirablethat the temperature of the concrete is maintained above approximately30° C. for 1 to approximately 7 days from the time of concreteplacement, preferably above approximately 35° C. for 1 to approximately7 days from the time of concrete placement, more preferably aboveapproximately 40° C. for 1 to approximately 7 days from the time ofconcrete placement, most preferably above approximately 45° C. for 1 toapproximately 7 days from the time of concrete placement. It is alsodesirable that the temperature of the concrete be maintained aboveambient temperature for 1 to approximately 3 days from the time ofconcrete placement; 1 to approximately 5 days from the time of concreteplacement, for 1 to approximately 7 days from the time of concreteplacement, for 1 to approximately 14 days from the time of concreteplacement, preferably approximately 3 to approximately 14 days from thetime of concrete placement, especially approximately 7 to approximately14 days from the time of concrete placement. It is also desirable thatthe temperature of the concrete be maintained above ambient temperaturefor approximately 3 days, approximately 5 days, approximately 7 days orapproximately 14 days from the time of concrete placement. It is furtherdesirable that the temperature of the concrete be reduced from themaximum temperature to ambient temperature gradually, such as inincrements of approximately 0.5 to approximately 5° C. per day,preferably approximately 1 to approximately 2° C. per day, especiallyapproximately 1° C. per day. The electrically heated blanket ispreferably kept on the curing concrete until the concrete is strongenough such that cracking due to temperature shrinkage will not occurfrom further cooling. Different curing temperature profiles may apply todifferent concrete mix designs and/or different materials used for thecementitious portion of the concrete mix in order to achieve a desiredconcrete strength or a desired concrete strength within a desired periodof time in different weather conditions. However, all curing temperatureprofiles in accordance with the present invention will have the samegeneral shape as shown in FIG. 11 relative to ambient temperature. Thus,as used herein the term “temperature profile” includes retaining theheat generated by the cement hydration reaction so as to increase theconcrete temperature above ambient temperature over a period of timefollowed by decreasing the concrete temperature over a period of timedue to the gradual loss of heat to the environment, preferably toambient temperature, wherein the slope of a line plotting temperatureversus time during the temperature increase phase is greater than theabsolute value of the slope of a line plotting temperature versus timeduring the temperature decrease phase. Furthermore, the absolute valueof the slope of a line plotting temperature versus time during thetemperature decrease phase of the temperature profile in a concrete formin accordance with the present invention is less than the absolute valueof the slope of a line plotting temperature versus time if all addedheat were stopped and the concrete were simply allowed to cool in aconventional concrete form; i.e., an uninsulated concrete form, or indirect contact with the environment under the same conditions. The term“temperature profile” includes the specific ranges of temperatureincrease and ranges of temperature decrease over ranges of time as setforth above with respect to FIG. 11. The term “temperature profile”includes increasing the temperature of curing concrete in a concreteform or mold to a maximum temperature at least 10% greater than themaximum temperature the same concrete mix would have reached in aconventional (i.e., non-insulated) concrete form or mold of the sameconfiguration. The term “temperature profile” also includes reducing thetemperature of curing concrete in a concrete form or mold from itsmaximum temperature at a rate slower than the rate the same concrete mixwould reduce from its maximum temperature in a conventional (i.e.,non-insulated) concrete form or mold of the same configuration. Theprinciple behind concrete maturity is the relationship between strength,time, and temperature in young concrete. Maturity is a powerful andaccurate means to predict early strength gain. Concrete maturity ismeasured as “equivalent age” and is given in temperature degrees x hours(either ° C.-Hrs or ° F.-Hrs). The term “temperature profile” includescontrolling the temperature of curing concrete so that at 3 days it hasa concrete maturity or equivalent age at least 25% greater than the sameconcrete mix would have in a conventional (i.e., non-insulated) concreteform or mold of the same configuration under the same conditions;preferably at least 30% greater, more preferably at least 35% greater,most preferably at least 40% greater, especially at least 45% greater,more especially at least 50% greater. The term “temperature profile”includes controlling the temperature of curing concrete so that at 3days it has a concrete maturity or equivalent age about 70% greater thanthe same concrete mix would have when cured in accordance with ASTMC-39; preferably at least 75% greater, more preferably at least 80%greater, most preferably at least 85% greater, especially at least 90%greater, more especially at least 95% greater, most especially at least100% greater. The term “temperature profile” includes controlling thetemperature of curing concrete so that at 7 days it has a concretematurity or equivalent age about 70% greater than the same concrete mixwould have when cured in accordance with ASTM C-39; preferably at least75% greater, more preferably at least 80% greater, most preferably atleast 85% greater, especially at least 90% greater, more especially atleast 95% greater, most especially at least 100% greater. The term“temperature profile” specifically does not include adding a constantamount of heat to the concrete followed by stopping adding heat to theconcrete, such as would be involved when turning an electrically heatedblanket or heated concrete form on and then turning the heated blanketor heated concrete form off. The term “temperature profile” specificallydoes not include heating the concrete to a desired temperature and thenturning off the heat.

While the present invention can be used with conventional concretemixes; i.e., concrete in which portland cement is the only cementitiousmaterial used in the concrete, it is preferred as a part of the presentinvention to use the concrete or mortar mixes disclosed in applicant'sU.S. Pat. No. 8,545,749 (the disclosure of which is incorporated hereinby reference in its entirety). Specifically, the concrete mix inaccordance with the present invention comprises cementitious material,aggregate and water sufficient to hydrate the cementitious material. Theamount of cementitious material used relative to the total weight of theconcrete varies depending on the application and/or the strength of theconcrete desired. Generally speaking, however, the cementitious materialcomprises approximately 25% to approximately 40% by weight of the totalweight of the concrete, exclusive of the water, or 300 lbs/yd³ ofconcrete (177 kg/m³) to 1,100 lbs/yd³ of concrete (650 kg/m³) ofconcrete. The water-to-cement ratio by weight is usually approximately0.25 to approximately 0.7. Relatively low water-to-cement materialsratios by weight lead to higher strength but lower workability, whilerelatively high water-to-cement materials ratios by weight lead to lowerstrength, but better workability. Aggregate usually comprises 70% to 80%by volume of the concrete. However, the relative amounts of cementitiousmaterial to aggregate to water are not a critical feature of the presentinvention; conventional amounts can be used. Nevertheless, sufficientcementitious material should be used to produce concrete with anultimate compressive strength of at least 1,000 psi, preferably at least2,000 psi, more preferably at least 3,000 psi, most preferably at least4,000 psi, especially up to about 10,000 psi or more. In particular,Ultra High Performance concrete, concrete panels or concrete elementswith compressive strengths of over 20,000 psi can be cast and curedusing the method of the present invention.

The aggregate used in the concrete used with the present invention isnot critical and can be any aggregate typically used in concrete. Theaggregate that is used in the concrete depends on the application and/orthe strength of the concrete desired. Such aggregate includes, but isnot limited to, fine aggregate, medium aggregate, coarse aggregate,sand, gravel, crushed stone, lightweight aggregate, recycled aggregate,such as from construction, demolition and excavation waste, and mixturesand combinations thereof.

The reinforcement of the concrete used with the present invention is nota critical aspect of the present invention and thus any type ofreinforcement required by design requirements can be used. Such types ofconcrete reinforcement include, but are not limited to, deformed steelbars, cables, post tensioned cables, pre-stressed cables, fibers, steelfibers, mineral fibers, synthetic fibers, carbon fibers, steel wirefibers, mesh, lath, and the like.

The preferred cementitious material for use with the present inventioncomprises portland cement; preferably portland cement and one of slagcement or fly ash; and more preferably portland cement, slag cement andfly ash. Slag cement is also known as ground granulated blast-furnaceslag (GGBFS). The cementitious material preferably comprises a reducedamount of or no portland cement and increased amounts of recycledsupplementary cementitious materials; e.g., slag cement, fly ash,energetically modified cement and/or volcanic ash. This results incementitious material and concrete that is more environmentallyfriendly. The portland cement can also be replaced, in whole or in part,by one or more cementitious materials other than portland cement, slagcement or fly ash. Such other cementitious or pozzolanic materialsinclude, but are not limited to, silica fume; metakaolin; rice hull (orrice husk) ash; ground burnt clay bricks; brick dust; bone ash; animalblood; clay; volcanic ash, energetically modified cement, othersiliceous, aluminous or aluminosiliceous materials that react withcalcium hydroxide in the presence of water; hydroxide-containingcompounds, such as sodium hydroxide, magnesium hydroxide, or any othercompound having reactive hydrogen groups, other hydraulic cements, otherpozzolanic materials and combinations thereof. The portland cement canalso be replaced, in whole or in part, by one or more inert or fillermaterials other than portland cement, slag cement or fly ash. Such otherinert or filler materials include, but are not limited to limestonepowder; calcium carbonate; titanium dioxide; quartz; or other finelydivided minerals that densify the hydrated cement paste.

The preferred cementitious material for use with a disclosed embodimentof the present invention comprises 0% to approximately 100% by weightportland cement. The range of 0% to approximately 100% by weightportland cement includes all of the intermediate percentages; such as,5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%,75%, 80%, 85%, 90% and 95%. The cementitious material of the presentinvention can also comprise 0% to approximately 90% by weight portlandcement, preferably 0% to approximately 80% by weight portland cement,preferably 0% to approximately 70% by weight portland cement, morepreferably 0% to approximately 60% by weight portland cement, mostpreferably 0% to approximately 50% by weight portland cement, especially0% to approximately 40% by weight portland cement, more especially 0% toapproximately 30% by weight portland cement, most especially 0% toapproximately 20% by weight portland cement, or 0% to approximately 10%by weight portland cement. In one disclosed embodiment, the cementitiousmaterial comprises approximately 10% to approximately 45% by weightportland cement, more preferably approximately 10% to approximately 40%by weight portland cement, most preferably approximately 10% toapproximately 35% by weight portland cement, especially approximately33⅓% by weight portland cement, most especially approximately 10% toapproximately 30% by weight portland cement. In another disclosedembodiment of the present invention, the cementitious material cancomprise approximately 5% by weight portland cement, approximately 10%by weight portland cement, approximately 15% by weight portland cement,approximately 20% by weight portland cement, approximately 25% by weightportland cement, approximately 30% by weight portland cement,approximately 35% by weight portland cement, approximately 40% by weightportland cement, approximately 45% by weight portland cement orapproximately 50% by weight portland cement or any sub-combinationthereof.

The preferred cementitious material for use in one disclosed embodimentof the present invention also comprises 0% to approximately 90% byweight slag cement, preferably approximately 10% to approximately 90% byweight slag cement, preferably approximately 20% to approximately 90% byweight slag cement, more preferably approximately 30% to approximately80% by weight slag cement, most preferably approximately 30% toapproximately 70% by weight slag cement, especially approximately 30% toapproximately 60% by weight slag cement, more especially approximately30% to approximately 50% by weight slag cement, most especiallyapproximately 30% to approximately 40% by weight slag cement. In anotherdisclosed embodiment the cementitious material comprises approximately33⅓% by weight slag cement. In another disclosed embodiment of thepresent invention, the cementitious material can comprise approximately5% by weight slag cement, approximately 10% by weight slag cement,approximately 15% by weight slag cement, approximately 20% by weightslag cement, approximately 25% by weight slag cement, approximately 30%by weight slag cement, approximately 35% by weight slag cement,approximately 40% by weight slag cement, approximately 45% by weightslag cement, approximately 50% by weight slag cement, approximately 55%by weight slag cement, approximately 60% by weight slag cement,approximately 65%, approximately 70% by weight slag cement,approximately 75% by weight slag cement, approximately 80% by weightslag cement, approximately 85% by weight slag cement or approximately90% by weight slag cement or any sub-combination thereof.

The preferred cementitious material for use in one disclosed embodimentof the present invention also comprises 0% to approximately 80% byweight fly ash, preferably approximately 10% to approximately 80% byweight fly ash, preferably approximately 10% to approximately 75% byweight fly ash, preferably approximately 10% to approximately 70% byweight fly ash, preferably approximately 10% to approximately 65% byweight fly ash, preferably approximately 10% to approximately 60% byweight fly ash, preferably approximately 10% to approximately 55% byweight fly ash, preferably approximately 10% to approximately 80% byweight fly ash, preferably approximately 10% to approximately 45% byweight fly ash, more preferably approximately 10% to approximately 40%by weight fly ash, most preferably approximately 10% to approximately35% by weight fly ash, especially approximately 33⅓% by weight fly ash.In another disclosed embodiment of the present invention, the preferredcementitious material comprises 0% by weight fly ash, approximately 5%by weight fly ash, approximately 10% by weight fly ash, approximately15% by weight fly ash, approximately 20% by weight fly ash,approximately 25% by weight fly ash, approximately 30% by weight flyash, approximately 35% by weight fly ash, approximately 40% by weightfly ash, approximately 45% by weight fly ash or approximately 80% byweight fly ash, approximately 55% by weight fly ash, approximately 60%by weight fly ash, approximately 65% by weight fly ash, approximately70% by weight fly ash or approximately 75% by weight fly ash,approximately 80% by weight fly ash or any sub-combination thereof.Preferably the fly ash has an average particle size of <10 μm; morepreferably 90% or more of the particles have a particles size of <10 μm.

The cementitious material for use in one disclosed embodiment of thepresent invention can optionally include 0.1% to approximately 10% byweight Wollastonite. Wollastonite is a calcium inosilicate mineral(CaSiO₃) that may contain small amounts of iron, magnesium, andmanganese substituted for calcium. In addition the cementitious materialcan optionally include 0.1-25% calcium oxide (quick lime), calciumhydroxide (hydrated lime), calcium carbonate or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups.

The cementitious material for use in one disclosed embodiment of thepresent invention can also optionally include inert fillers, such aslimestone powder; calcium carbonate; titanium dioxide; quartz; or otherfinely divided minerals that densify the hydrated cement paste.Specifically, inert fillers optionally can be used in the cementitiousmaterial of the present invention in amounts of 0% to approximately 40%by weight; preferably, approximately 5% to approximately 30% by weight.In one disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 100% by weight portlandcement, approximately 10% to approximately 90% by weight slag cement,approximately 5% to approximately 80% by weight fly ash and 0% toapproximately 40% by weight inert filler. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 100% by weight portlandcement; at least one of approximately 10% to approximately 90% by weightslag cement and approximately 5% to approximately 80% by weight fly ash;and 5% to approximately 40% by weight inert filler.

In one disclosed embodiment, the preferred cementitious material for usewith the present invention comprises approximately equal parts by weightof portland cement, slag cement and fly ash; i.e., approximately 33⅓% byweight portland cement, approximately 33⅓% by weight slag cement andapproximately 33⅓% by weight fly ash. In another disclosed embodiment, apreferred cementitious material for use with the present invention has aweight ratio of portland cement to slag cement to fly ash of 1:1:1. Inanother disclosed embodiment, the preferred cementitious material foruse with the present invention has a weight ratio of portland cement toslag cement to fly ash of approximately 0.85-1.15:0.85-1.15:0.85-1.15,preferably approximately 0.9-1.1:0.9-1.1:0.9-1.1, more preferablyapproximately 0.95-1.05:0.95-1.05:0.95-1.05.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 100% byweight Portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 80% by weight flyash. In one disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 80%by weight Portland cement, approximately 10% to approximately 90% byweight slag cement, and approximately 5% to approximately 80% by weightfly ash. In another disclosed embodiment, the cementitious material foruse with the present invention comprises approximately 10% toapproximately 70% by weight Portland cement, approximately 10% toapproximately 90% by weight slag cement, and approximately 5% toapproximately 80% by weight fly ash. In another disclosed embodiment,the cementitious material for use with the present invention comprisesapproximately 10% to approximately 60% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 50% by weightPortland cement, approximately 10% to approximately 90% by weight slagcement, and approximately 5% to approximately 80% by weight fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises less than 50% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 45% by weightPortland cement, approximately 10% to approximately 90% by weight slagcement, and approximately 5% to approximately 80% by weight fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 40% byweight Portland cement, approximately 10% to approximately 90% by weightslag cement, and approximately 5% to approximately 80% by weight flyash. In another disclosed embodiment, the cementitious material for usewith the present invention comprises approximately 10% to approximately35% by weight Portland cement, approximately 10% to approximately 90% byweight slag cement, and approximately 5% to approximately 80% by weightfly ash.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 100% by weight Portlandcement, approximately 10% to approximately 90% by weight slag cement,and approximately 5% to approximately 80% by weight fly ash. In onedisclosed embodiment, the cementitious material for use with the presentinvention comprises 0% to approximately 80% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises 0% to approximately 70% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises 0% to approximately 60% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises 0% to approximately 50% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises 0% to approximately 45% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises 0% to approximately 40% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises 0% to approximately 35% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement, andapproximately 5% to approximately 80% by weight fly ash.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 100%by weight Portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight fly ash. In another disclosed embodiment,the cementitious material for use with the present invention comprisesapproximately 10% to approximately 90% by weight Portland cement and atleast one of approximately 10% to approximately 90% by weight slagcement and approximately 5% to approximately 80% by weight fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 80% byweight Portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight fly ash. In another disclosed embodiment,the cementitious material for use with the present invention comprisesapproximately 10% to approximately 70% by weight Portland cement and atleast one of approximately 10% to approximately 90% by weight slagcement and approximately 5% to approximately 80% by weight fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 60% byweight Portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight fly ash. In another disclosed embodiment,the cementitious material for use with the present invention comprisesapproximately 10% to approximately 50% by weight Portland cement and atleast one of approximately 10% to approximately 90% by weight slagcement and approximately 5% to approximately 80% by weight fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 40% byweight Portland cement and at least one of approximately 10% toapproximately 90% by weight slag cement and approximately 5% toapproximately 80% by weight fly ash.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 90%by weight Portland cement; approximately 10% to approximately 90% byweight slag cement; 0% to approximately 80% by weight fly ash; 0% to 10%by weight Wollastonite; and 0% to approximately 25% by weight calciumoxide, calcium hydroxide, or latex or polymer admixtures, either mineralor synthetic, that have reactive hydroxyl groups, or mixtures thereof.In one disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 80% byweight Portland cement; approximately 10% to approximately 90% by weightslag cement; 0% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 70% by weight Portland cement; approximately 10% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 10% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 60% by weight Portlandcement; approximately 10% to approximately 90% by weight slag cement; 0%to approximately 80% by weight fly ash; 0% to approximately 10% byweight Wollastonite; and 0% to approximately 25% by weight calciumoxide, calcium hydroxide, or latex or polymer admixtures, either mineralor synthetic, that have reactive hydroxyl groups, or mixtures thereof.In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 50%by weight Portland cement; approximately 10% to approximately 90% byweight slag cement; 0% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises less than 50% byweight Portland cement; approximately 10% to approximately 90% by weightslag cement; approximately 10% to approximately 80% by weight fly ash;0% to approximately 10% by weight Wollastonite; and 0% to approximately25% by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight Portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; 0% to approximately 10% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 40% byweight Portland cement; approximately 10% to approximately 90% by weightslag cement; approximately 10% to approximately 80% by weight fly ash;0% to approximately 10% by weight Wollastonite; and 0% to approximately25% by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 35% by weight Portland cement;approximately 10% to approximately 90% by weight slag cement;approximately 10% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises at least one of approximately 10% toapproximately 100% by weight Portland cement, approximately 10% toapproximately 90% by weight slag cement or approximately 5% toapproximately 80% by weight fly ash; 0% to 10% by weight Wollastonite;and 0% to approximately 25% by weight calcium oxide, calcium hydroxide,or latex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In one disclosedembodiment, the cementitious material for use with the present inventioncomprises at least one of approximately 10% to approximately 80% byweight Portland cement, approximately 10% to approximately 90% by weightslag cement or approximately 5% to approximately 80% by weight fly ash;0% to approximately 10% by weight Wollastonite; and 0% to approximately25% by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof. In another disclosed embodiment, thecementitious material for use with the present invention comprises atleast one of approximately 10% to approximately 70% by weight Portlandcement, approximately 10% to approximately 90% by weight slag cement orapproximately 5% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises at least one ofapproximately 10% to approximately 60% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement orapproximately 5% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises at least one ofapproximately 10% to approximately 50% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement orapproximately 5% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises less than 50% byweight Portland cement; approximately 10% to approximately 90% by weightslag cement; approximately 10% to approximately 80% by weight fly ash;0% to approximately 10% by weight Wollastonite; and 0% to approximately25% by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof. In another disclosed embodiment, thecementitious material for use with the present invention comprises atleast one of approximately 10% to approximately 45% by weight Portlandcement, approximately 10% to approximately 90% by weight slag cement orapproximately 10% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises at least one ofapproximately 10% to approximately 40% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement orapproximately 10% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises at least one ofapproximately 10% to approximately 35% by weight Portland cement,approximately 10% to approximately 90% by weight slag cement orapproximately 10% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 90%by weight Portland cement; at least one of approximately 10% toapproximately 90% by weight slag cement or approximately 5% toapproximately 80% by weight fly ash; and 0.1% to 10% by weightWollastonite. In one disclosed embodiment, the cementitious material foruse with the present invention comprises approximately 10% toapproximately 80% by weight Portland cement; at least one ofapproximately 10% to approximately 90% by weight slag cement orapproximately 5% to approximately 80% by weight fly ash; and 0.1% toapproximately 10% by weight Wollastonite. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 70% by weight Portlandcement; at least one of approximately 10% to approximately 90% by weightslag cement or approximately 5% to approximately 80% by weight fly ash;and 0.1% to approximately 10% by weight Wollastonite. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 60% by weightPortland cement; at least one of approximately 10% to approximately 90%by weight slag cement or approximately 5% to approximately 80% by weightfly ash; and 0.1% to approximately 10% by weight Wollastonite. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 50% byweight Portland cement; at least one of approximately 10% toapproximately 90% by weight slag cement or approximately 5% toapproximately 80% by weight fly ash; and 0.1% to approximately 10% byweight Wollastonite. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises less than 50% byweight Portland cement; at least one of approximately 10% toapproximately 90% by weight slag cement or approximately 5% toapproximately 80% by weight fly ash; and 0.1% to approximately 10% byweight Wollastonite. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 45% by weight Portland cement; at least one ofapproximately 10% to approximately 90% by weight slag cement orapproximately 5% to approximately 80% by weight fly ash; and 0.1% toapproximately 10% by weight Wollastonite. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 40% by weight Portlandcement; at least one of approximately 10% to approximately 90% by weightslag cement or approximately 5% to approximately 80% by weight fly ash;and 0.1% to approximately 10% by weight Wollastonite. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 35% by weightPortland cement; at least one of approximately 10% to approximately 90%by weight slag cement or approximately 5% to approximately 80% by weightfly ash; and 0.1% to approximately 10% by weight Wollastonite.

The portland cement, slag cement and fly ash can be combined physicallyor mechanically in any suitable manner and is not a critical feature.For example, the portland cement, slag cement and fly ash can be mixedtogether to form a uniform blend of dry material prior to combining withthe aggregate and water. Or, the portland cement, slag cement and flyash can be added separately to a conventional concrete mixer, such asthe transit mixer of a ready-mix concrete truck, at a batch plant. Thewater and aggregate can be added to the mixer before the cementitiousmaterial, however, it is preferable to add the cementitious materialfirst, the water second, the aggregate third and any makeup water last.

Chemical admixtures can also be used with the preferred concrete for usewith the present invention. Such chemical admixtures include, but arenot limited to, accelerators, retarders, air entrainments, plasticizers,superplasticizers, coloring pigments, corrosion inhibitors, bondingagents and pumping aid. Although chemical admixtures can be used withthe concrete of the present invention, it is believed that chemicaladmixtures are not necessary.

Mineral admixtures or supplementary cementitious materials (SCMs) canalso be used with the concrete of the present invention. Such mineraladmixtures include, but are not limited to, silica fume; metakaolin;rice hull (or rice husk) ash; ground burnt clay bricks; brick dust; boneash; animal blood; clay; other siliceous, aluminous or aluminosiliceousmaterials that react with calcium hydroxide in the presence of water;hydroxide-containing compounds, such as sodium hydroxide, magnesiumhydroxide, or any other compound having reactive hydrogen groups, otherhydraulic cements and other pozzolanic materials. Although mineraladmixtures can be used with the concrete of the present invention, it isbelieved that mineral admixtures are not necessary.

The concrete mix cured in an insulated concrete form in accordance withthe present invention, produces concrete with superior early strengthand ultimate strength properties compared to the same concrete mix curedin a conventional form without the use of any chemical additives toaccelerate or otherwise alter the curing process. Thus, in one disclosedembodiment of the present invention, the preferred cementitious materialcomprises at least two of portland cement, slag cement and fly ash inamounts such that at three to seven days the concrete mix cured inaccordance with the present invention has a compressive strength atleast 50% greater than the same concrete mix would have after the sameamount of time in a conventional (i.e., non-insulated) concrete formunder ambient conditions. In another disclosed embodiment, the preferredconcrete mix cured in accordance with the present invention has acompressive strength at least 25%, at least 50%, at least 75%, at least100%, at least 150%, at least 200%, at least 250% or at least 300%greater than the same concrete mix would have after the same amount oftime in a conventional (i.e., non-insulated) concrete form under thesame conditions.

In another disclosed embodiment of the present invention, the preferredcementitious material comprises portland cement, slag cement and fly ashin amounts such that at three to seven days the concrete mix cured inaccordance with the present invention has a compressive strength atleast 25% or at least 50% greater than the same concrete mix would haveafter three days in a conventional concrete form under ambientconditions. In another disclosed embodiment the preferred concrete mixcured in accordance with the present invention has a compressivestrength at least 25%, at least 50%, at least 75%, at least 100%, atleast 150%, at least 200%, at least 250% or at least 300% greater thanthe same concrete mix would have after the same amount of time in aconventional (i.e., non-insulated) concrete form under the sameconditions.

In another disclosed embodiment of the present invention, the preferredcementitious material comprises portland cement and slag cement inamounts such that at three to seven days the concrete mix cured inaccordance with the present invention has a compressive strength atleast 25% or at least 50% greater than the same concrete mix would haveafter the same time period in a conventional concrete form under ambientconditions. In another disclosed embodiment, the preferred concrete mixcured in accordance with the present invention has a compressivestrength at least 100%, at least 150%, at least 200%, at least 250% orat least 300% greater than the same concrete mix would have after thesame amount of time in a conventional (i.e., non-insulated) concreteform under the same conditions.

In another disclosed embodiment of the present invention, the preferredcementitious material comprises portland cement and fly ash in amountssuch that at three to three to seven days the concrete mix cured inaccordance with the present invention has a compressive strength atleast 25% or at least 50% greater than the same concrete mix would haveafter the same time period in a conventional concrete form under ambientconditions. In another disclosed embodiment the preferred concrete mixcured in accordance with the present invention has a compressivestrength at least 100%, at least 150%, at least 200%, at least 250% orat least 300% greater than the same concrete mix would have after thesame amount of time in a conventional (i.e., non-insulated) concreteform under the same conditions.

The present invention can be used to form any type of concrete structureor object, either cast in place or precast. The present invention can beused to form footings, retaining walls, exterior walls of buildings,load-bearing interior walls, columns, piers, parking deck slabs,elevated slabs, roofs, bridges, or any other structures or objects.Also, the present invention can be used to form precast structures orobjects, tilt-up concrete panels for exterior walls of buildings,load-bearing interior walls, columns, piers, parking deck slabs,elevated slab, roofs and other similar precast structures and objects.Additionally, the present invention can be used to form precaststructures including, but not limited to, walls, floors, decking, beams,railings, pipes, vaults, underwater infrastructure, modular pavingproducts, retaining walls, storm water management products, culverts,bridge systems, railroad ties, traffic barriers, tunnel segments, lightpole beams, light pole bases, transformer pads, and the like.

It should be understood, of course, that the foregoing relates only tocertain disclosed embodiments of the present invention and that numerousmodifications or alterations may be made therein without departing fromthe spirit and scope of the invention as set forth in the appendedclaims.

What is claimed is:
 1. A concrete casting table comprising: a firsthorizontal concrete forming panel having a first primary surface adaptedfor forming and contacting plastic concrete and a second primary surfaceopposite the first primary surface, wherein the first concrete formingpanel defines a plane; a second horizontal panel having a first primarysurface and a second primary surface opposite the first primary surface;a first continuous layer of insulating material continuously contactingthe second primary surface of the first concrete forming panel and thesecond primary surface of the second panel, the layer of insulatingmaterial substantially covering the second primary surface of the firstpanel; a plurality of vertical side members, each of which has a firstprimary surface adapted for forming plastic concrete and a secondprimary surface opposite the first primary surface, wherein the firsthorizontal concrete forming panel and the plurality of vertical sidemembers define a concrete mold cavity; a second continuous layer ofinsulating material substantially covering the second primary surface ofeach of the plurality of vertical side members; a removable third layerof insulating material covering the concrete mold cavity, and a framedisposed on the first primary surface of the second panel, the framecomprising a plurality of bracing members oriented transversely withrespect to the first primary surface of the second panel, wherein noportion of the frame is in the plane defined by the first concreteforming panel.
 2. The concrete casting table of claim 1, wherein thefirst and second continuous layers of insulating material each comprisea conductive heat insulating material or a radiant heat reflectivematerial.
 3. The concrete casting table of claim 1, wherein the firstand second continuous layers of insulating material each have insulatingproperties equivalent to at least 0.25 inch of polystyrene foam.
 4. Theconcrete casting table of claim 1, wherein the first and secondcontinuous layers of insulating material each have insulating propertiesequivalent to at least 0.5 inch of polystyrene foam.
 5. The concretecasting table of claim 1, wherein the first and second continuous layersof insulating material each have insulating properties equivalent to atleast 1 inch of polystyrene foam.
 6. The concrete casting table of claim1, wherein the first and second continuous layers of insulating materialeach have insulating properties equivalent to at least 2 inches ofpolystyrene foam.
 7. The concrete casting table of claim 1, wherein thefirst and second continuous layers of insulating material each comprisesa layer of refractory insulating material in an adhesive.
 8. Theconcrete casting table of claim 1, wherein the first and secondcontinuous layers of insulating material each comprises a layer ofceramic fibers in an adhesive.
 9. The concrete casting table of claim 8,wherein the adhesive is polyurethane or epoxy.
 10. The concrete castingtable of claim 1, wherein the first and second continuous layers ofinsulating material each comprises Wollastonite in an adhesive.
 11. Theconcrete casting table of claim 1, wherein the first and secondcontinuous layers of insulating material each comprises closed cellpolymeric foam.
 12. The concrete casting table of claim 1, wherein thefirst and second continuous layers of insulating material each comprisea rigid insulating polymeric foam.
 13. The concrete casting table ofclaim 1, wherein the first and second continuous layers of insulatingmaterial each comprise a polymeric foam of polyvinyl chloride, urethane,polyurethane, polyisocyanurate, phenol, polyethylene, polyimide orexpanded polystyrene.
 14. The concrete casting table of claim 1, whereinthe removable third layer of insulating material has insulatingproperties equivalent to at least 1 inch of polystyrene foam.
 15. Theconcrete casting table of claim 1, wherein the removable third layer ofinsulating material has insulating properties equivalent to at least 2inch of polystyrene foam.
 16. The concrete casting table of claim 1,wherein the removable third layer of insulating material comprises apolymeric foam of polyvinyl chloride, urethane, polyurethane,polyisocyanurate, phenol, polyethylene, polyimide or expandedpolystyrene.
 17. The concrete casting table of claim 14, wherein theremovable third layer of insulating material comprises a polymeric foamof polyvinyl chloride, urethane, polyurethane, polyisocyanurate, phenol,polyethylene, polyimide or expanded polystyrene.
 18. The concrete formof claim 15, wherein the removable third layer of insulating materialcomprises a polymeric foam of polyvinyl chloride, urethane,polyurethane, polyisocyanurate, phenol, polyethylene, polyimide orexpanded polystyrene.
 19. The concrete form of claim 6, wherein theremovable third layer of insulating material has insulating propertiesequivalent to at least 2 inch of polystyrene foam.